Lamination inflatable sports ball

ABSTRACT

A sports ball includes an inflatable ball bladder having an outer spherical surface, and a plurality of laminating laves. The plurality of laminating leaves are overlappedly attached to the outer spherical surface of the ball bladder, wherein each of the laminating leaves, which is constructed from a plurality of polygon panels, has a plurality of peripheral alignment edges arranged when the alignment edges are connected correspondingly, the laminating leaves forms a portion of a spherical casing such that when the laminating leaves are connected edge-to-edge, the spherical casings form a spherical carcass of the ball bladder.

BACKGROUND OF THE PRESENT INVENTION

1. Field of Invention

The present invention relates to a ball, and more particularly to asports ball having a simple structure and a manufacturing method.However, a strength and optimal hardness of the sports ball aresubstantially preserved as compared with conventional sports ball.

2. Description of Related Arts

A conventional sports ball usually comprises an inflatable ball bladderand an outer ball carcass which comprises a plurality of carcass panelsoverlappedly attached on the outer surface of the inflatable ballbladder. In order to ensure an overall strength and performance of thesports ball, each of the carcass panels is usually sewed with anadjacent piece of the carcass panels so as to prevent the outer ballcarcass from breaking too easily.

As a matter of conventional art, there exist many methods by which thesports ball can be manufactured. Due to sewing requirement of the outerball carcass, most of the manufacturing methods are complicated andrequire high degree of precision. This inevitably increases the cost ofthe sports ball and therefore increases the ultimate selling pricethereof.

Accordingly, a conventional method for manufacturing the sports ballcomprises the following steps.

1. Cut a material sheet into a plurality of outer cover skins, includinghexagon shaped panels and pentagon shaped panels when a soccer ball ismade.

2. Sew the cover skins together in an edge to edge manner to form a ballcarcass, wherein thirty two pieces of the cover skins are required toform the ball carcass, wherein an edge section of the ball carcass isnot sewn to form the inlet opening.

3. Insert the inflatable blabber into the ball carcass through the inletopening.

4. Sew up the inlet opening to form the sports ball.

Even for the those conventional balls which do not need sewing of theouter ball carcass, such as a basketball, the inflatable ball bladderusually has a plurality of carcass channels wherein each of the carcasspanels is attached on the inflatable ball bladder alone thecorresponding carcass channels. Presumably, the main reason for doingthat is to maximize the overall cushion effect of the relevant sportsballs without significantly increasing the sizes thereof. Thismanufacturing method is no less complicated since each piece of thecarcass panels has to be attached on the inflatable sports ballprecisely at predetermined position in between each two adjacent carcasschannels.

SUMMARY OF THE PRESENT INVENTION

A main object of the present invention is to provide a sports ballhaving a simple structure and a manufacturing method. However, thestrength and the optimal hardness of the sports ball are substantiallypreserved as compared with conventional sports ball.

Another object of the present invention is to provide a sports ballwhich comprises a plurality of laminating leaves attaching on a smoothinflatable ball bladder without sewing with each other, wherein each ofthe laminating leaves is constructed as an integral piece of polygon forforming the outer ball carcass of the present invention.

Another object of the present invention is to provide a sports ball,wherein each of the laminating leaves are first subject to embossingprocess before they are attached on the inflatable ball bladder, so asto preserve an optimal cushion effect of the present invention.

Another object of the present invention is to provide a sports ballwhich is easy to manufacture so as to minimize the manufacturing cost ofthe present invention.

Accordingly, in order to accomplish the above objects, the presentinvention provides a sports ball, comprising:

an inflatable ball bladder having an outer spherical surface; and

a plurality of laminating leaves overlappedly attached to the outerspherical surface of the ball bladder, wherein each of the laminatingleaves, which is constructed from a plurality of polygon panels, has aplurality of peripheral alignment edges arranged when the alignmentedges are connected correspondingly, the laminating leaves forms aportion of a spherical casing such that when the laminating leaves areconnected edge-to-edge, the spherical casings form a spherical carcassof the ball bladder.

Moreover, the present invention also provides a method of manufacturinga sports ball, comprising the steps of:

(a) providing an inflatable ball bladder having an outer sphericalsurface;

(b) cutting a carcass sheet in a plurality of laminating leaves, whereineach of the laminating leaves, which is constructed from a plurality ofpolygon panels, has a plurality of peripheral alignment edges arrangedwhen the alignment edges are connected correspondingly, the laminatingleaves forms a portion of a spherical casing; and

(c) overlappedly attaching to the outer spherical surface of the ballbladder, wherein when the laminating leaves are connected edge-to-edge,the spherical casings form a spherical carcass of the ball bladder.

These and other objectives, features, and advantages of the presentinvention will become apparent from the following detailed description,the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a sports ball according to a preferredembodiment of the present invention.

FIG. 2 is a sectional side view of the sports ball according to theabove preferred embodiment of the present invention.

FIG. 3 is schematic diagrams of the method of manufacturing the sportsball according to the above preferred embodiment of the presentinvention.

FIG. 4 is a flow diagram of a method of manufacturing the sports ballaccording to the above preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1 and FIG. 2 of the drawings, a sports ball, such as amini soccer ball, according to a preferred embodiment of the presentinvention is illustrated, in which the sports ball comprises aninflatable ball bladder 10 having a smooth outer spherical surface 11,and a plurality of laminating leaves 20.

The plurality of laminating leaves 20 is overlappedly attached to theouter spherical surface 11 of the ball bladder 10, wherein each of thelaminating leaves 20, which is constructed from a plurality of polygonpanels 21, has a plurality of peripheral alignment edges 22 arrangedwhen the alignment edges 22 are connected correspondingly, thelaminating leaves 20 forms a portion of a spherical casing such thatwhen the laminating leaves 20 are connected edge-to-edge, the sphericalcasings form a spherical ball carcass 23 of the ball bladder 10.

According to the preferred embodiment of the present invention, each ofthe polygon panels 21 forms a predetermined polygon having thecorresponding shape of the respective polygon. Accordingly, each of thelaminating leaves 20 has a central portion and the plurality of polygonpanels 21 integrally extended from the central portion to form therespective laminating leave 20 having the corresponding peripheralalignment edges 22. For instances, as shown in FIG. 1 of the drawings,each of the laminating leaves 20 is constructed by five hexagons andthree pentagons, so that each of the hexagons forms six of theperipheral edges 22, and each pentagon forms five of the peripheraledges 22.

The laminating leaves 20 are preferably made of flexible and durablematerials, such as leather, rubber, PU etc., so that they can befittedly attached on the outer spherical surface 11 of the inflatableball bladder 10, with the peripheral alignment edges 22 correspondinglyconnected. On the other hand, the inflatable ball bladder 10 ispreferably fabricated by conventional materials which are utilized inconventional inflatable ball bladders such as rubber or PU so that theinflatable ball bladder 10 is capable of being effectively attached bythe laminating leaves 20.

Referring to FIG. 2 of the drawings, the sports ball further comprisesan adhesive layer 30 provided between the laminating leaves 20 and theouter spherical surface 11 of the inflatable ball bladder 10 forproviding an adhesive effect between the laminating leaves 20 and theinflatable ball bladder 10. The adhesive layer 30 is preferably embodiedas conventional adhesive materials for binding the laminating leaves 20with the outer spherical surface 111 of the inflatable ball bladder 10.

It is then worth emphasizing that the outer spherical surface 11 of theinflatable ball bladder 10 should be smooth (i.e. with any windings orchannels) so that the laminating leaves 20 are capable of fittedly andsecurely attached on that outer spherical surface 11 by the adhesivelayer 30. In other words, no guiding line is formed on the outerspherical surface 11 of the inflatable ball bladder 10 to guide thelaminating leaves 20 overlapping thereon.

In order to achieve an optimal cushion effect of the sports ball, eachof the laminating leaves 20 are embossed, preferably by conventionalembossing processes, in the peripheral alignment edges 22 so as tocreate a predetermined slope thereon with respect to the correspondingpolygon panels 21 such that when the laminating leaves 20 are attachedon the inflatable ball bladder 10, each of the polygon panels 21 form aslope effect at the corresponding peripheral alignment edges 22 forcreating the cushion effect of the sports ball. In other words, each ofthe laminating leaves 20 are embossed in the peripheral alignment edges22 to create a predetermined slope thereon with respect to thecorresponding polygon panels 21 so as to stand out the shapes of thepolygon panels 21 protruding on the ball bladder 10 when the laminatingleaves 20 are attached on the inflatable ball bladder 10.

Moreover, since each of the laminating leaves 20 is securely attached onthe inflatable ball bladder 10 in such a manner that polygon panels 21are connected edge-to-edge at the corresponding peripheral alignmentedges 22, each two corresponding adjacent peripheral alignment edges 22will form a sew sewn effect between those two corresponding peripheralalignment edges 22 without actually sewing thereof. In other words, thesports ball of the present invention can be embodied as closelyresembling the appearance of conventional sports ball so as to maximizewidespread acceptance of the present invention.

According to the preferred embodiment of the present invention, thesports ball comprises altogether four identical pieces of the laminatingleaves 20 which are to be attached on the inflatable ball bladder 10 forfittedly aligning the corresponding peripheral alignment edges 22 so asto form the spherical carcass of the inflatable ball bladder 10, suchthat each of the laminating leaves 20 form a quarter of the sphericalcarcass.

It is worth mentioning that the number of pieces of the laminatingleaves 20 utilized in forming the spherical carcass would ultimatelydepend on the size of the sports ball and the purpose for which thesports ball is utilized. For instances, whereas four pieces oflaminating leaves 20 may be utilized to form a mini sports ball, eightlaminating leaves 20 may be utilized for forming a full-sized soccerball.

Referring to FIG. 3 to FIG. 4 of the drawings, a method of manufacturinga sports ball is illustrated, in which the manufacturing methodcomprises the steps of:

(a) providing an inflatable ball bladder 10 having an outer sphericalsurface 11;

(b) cutting a carcass sheet in a plurality of laminating leaves 20,wherein each of the laminating leaves 20, which is constructed from aplurality of polygon panels 21, has a plurality of peripheral alignmentedges 22 arranged when the alignment edges 22 are connectedcorrespondingly, the laminating leaves 20 forms a portion of a sphericalcasing; and

(c) overlappedly adhering the laminating leaves 20 to the outerspherical surface 11 of the inflatable ball bladder 10, wherein when thelaminating leaves 20 are connected edge-to-edge, the spherical casingsform a spherical carcass of the inflatable ball bladder 10.

In order to create the sewing seam effect, step (b) comprises a sub-step(b.1) of pre-embossing each of the laminating leaves 20 at thecorresponding peripheral alignment edges 22 so as to create apredetermined slope thereon with respect to the corresponding polygonpanels 21, such that when the laminating leaves 20 are attached on theinflatable ball bladder 10, each of the polygon panels 21 form a slopeeffect at the corresponding peripheral alignment edges 22 for creatingthe cushion effect of the sports ball. In other words, the shapes of thepolygon panels 21 are protruded on the ball bladder 10 when thelaminating leaves 20 are attached on the inflatable ball bladder 10.

In order to overlappedly attach the laminating leaves 20 on theinflatable ball bladder 10, step (c) comprises the steps of:

(c.1) applying an adhesive layer 30 on the outer spherical surface 11 ofthe inflatable ball bladder 10;

(c.2) aligning each of the peripheral alignment edges 22 with acorresponding adjacent peripheral alignment edge 22; and

(c.3) overlapping the laminating leaves 20 on the outer sphericalsurface 11 wherein the adhesive layer 30 securely binds the laminatingleaves 20 with the outer spherical surface 11 of the inflatable ballbladder 10 to form the spherical carcass of the sports ball of thepresent invention.

The laminating leaves 20 are overlappedly attached on the ball bladder10 in a spherical mold machine for minimizing a manufacturing timerequired to sew the laminating leaves 20 together so as to reduce amanufacturing cost of the sports ball. It is worth mentioning that thesports ball of the present invention is manufacture by a molding methodusing a spherical mold machine, in which case the manufacturing methodfurther comprises the steps, in between step (b) and step (c) of:

providing a spherical mold having an interior cavity and a plurality ofembossing ribs formed on an interior spherical wall of the interiorcavity;

slightly attaching outer surfaces of the laminating leaves 20 on theinterior spherical wall; and

disposing the inflatable ball bladder 10 into the interior cavity of thespherical mold.

Furthermore, the step (c) further comprises the steps of:

(c.1′) applying an adhesive layer 30 on the outer spherical surface 11of the inflatable ball bladder 10;

(c.2′) aligning each of the peripheral alignment edges 22 with acorresponding peripheral alignment edge 22;

(c.3′) inflating the inflatable ball bladder 10 in the spherical cavityof the spherical mold so as to overlap the laminating leaves 20 on theouter spherical surface 11, wherein the adhesive layer 30 securely bindsthe laminating leaves 20 with the outer spherical surface 11 of theinflatable ball bladder 10 while the peripheral alignment edges 22 areembossed by the corresponding embossing ribs to form the sphericalcarcass of the sports ball of the present invention.

At this point, it is worth mentioning that a regular spherical mold(without the embossing ribs) may be utilized. In such a case however,the above-mentioned sub-step (b.1) is needed to pre-emboss each of theperipheral alignment edges 22 before the laminating leaves 20 areattached on the mold.

One skilled in the art may appreciate that the above-mentionedmanufacturing method is extremely simple. The laminating leaves 20 usedto form the sports ball is preferably four in number. As a result, themanufacturer of the sports ball of the present invention does not needto sew every single laminating leaves 20 with the adjacent one while theoverall effect of the present invention is perfectly comparable withconventional sports ball. Where a larger sports ball is preferred, thenumber of laminating leaves 20 can be increased to eight or even more.

From the forgoing descriptions, it can be shown that the above-mentionedobjects have been substantially accomplished. The present inventionprovides a sports ball having a simple structure and a manufacturingmethod of that sports ball. Note that the strength and the optimalhardness of the sports ball are substantially preserved as compared withconventional sports ball.

One skilled in the art will understand that the embodiment of thepresent invention as shown in the drawings and described above isexemplary only and not intended to be limiting.

It will thus be seen that the objects of the present invention have beenfully and effectively accomplished. It embodiments have been shown anddescribed for the purposes of illustrating the functional and structuralprinciples of the present invention and is subject to change withoutdeparture from such principles. Therefore, this invention includes allmodifications encompassed within the spirit and scope of the followingclaims.

1. A sports ball, comprising: an inflatable ball bladder having an outerspherical surface; and a plurality of laminating leaves overlappedlyattached to said outer spherical surface of said ball bladder, whereineach of said laminating leaves, which is constructed from a plurality ofpolygon panels, has a plurality of peripheral alignment edges arrangedwhen said alignment edges are connected correspondingly, said laminatingleaves forms a portion of a spherical casing such that when saidlaminating leaves are connected edge-to-edge, said spherical casingsform a spherical carcass of said ball bladder.
 2. The sports ball, asrecited in claim 1, wherein each of said laminating leaves are embossedin said peripheral alignment edges to create a predetermined slopethereon with respect to said corresponding polygon panels so as to standout the shapes polygon panels protruding on said ball bladder when saidlaminating leaves are attached on said inflatable ball bladder.
 3. Thesports ball, as recited in claim 2, wherein each of said laminatingleaves is securely attached on said inflatable ball bladder in such amanner that said polygon panels are connected edge-to-edge at saidcorresponding peripheral alignment edges, wherein each of said twocorresponding adjacent peripheral alignment edges form a sewing sewneffect between said two corresponding peripheral alignment edges of saidsports ball.
 4. The sports ball, as recited in claim 1, wherein each ofsaid laminating leaves is constructed by five hexagonal polygon panelsand three pentagonal polygon panels integrally extended therefrom in anedge-to-edge manner, so as to form said peripheral alignment edges atsaid edges of said hexagonal polygon panels and three pentagonal polygonpanels respectively.
 5. The sports ball, as recited in claim 2, whereineach of said laminating leaves is constructed by five hexagonal polygonpanels and three pentagonal polygon panels integrally extended therefromin an edge-to-edge manner, so as to form said peripheral alignment edgesat said edges of said hexagonal polygon panels and three pentagonalpolygon panels respectively.
 6. The sports ball, as recited in claim 3,wherein each of said laminating leaves is constructed by five hexagonalpolygon panels and three pentagonal polygon panels integrally extendedtherefrom in an edge-to-edge manner, so as to form said peripheralalignment edges at said edges of said hexagonal polygon panels and threepentagonal polygon panels respectively.
 7. The sports ball, as recitedin claim 1, being formed by four identical pieces of said laminatingleaves which are to be attached on said inflatable ball bladder forfittedly aligning said corresponding peripheral alignment edges so as toform said spherical carcass of said inflatable ball bladder, such thateach of said laminating leaves form a quarter of said spherical carcass.8. The sports ball, as recited in claim 3, being formed by fouridentical pieces of said laminating leaves which are to be attached onsaid inflatable ball bladder for fittedly aligning said correspondingperipheral alignment edges so as to form said spherical carcass of saidinflatable ball bladder, such that each of said laminating leaves form aquarter of said spherical carcass.
 9. The sports ball, as recited inclaim 6, being formed by four identical pieces of said laminating leaveswhich are to be attached on said inflatable ball bladder for fittedlyaligning said corresponding peripheral alignment edges so as to formsaid spherical carcass of said inflatable ball bladder, such that eachof said laminating leaves form a quarter of said spherical carcass. 10.The sports ball, as recited in claim 1, further comprising an adhesivelayer provided between said laminating leaves and said outer sphericalsurface of said inflatable ball bladder for providing an adhesive effectbetween said laminating leaves and said inflatable ball bladder so as tosecurely bind said laminating leaves with said outer spherical surfaceof said inflatable ball bladder.
 11. The sports ball, as recited inclaim 3, further comprising an adhesive layer provided between saidlaminating leaves and said outer spherical surface of said inflatableball bladder for providing an adhesive effect between said laminatingleaves and said inflatable ball bladder so as to securely bind saidlaminating leaves with said outer spherical surface of said inflatableball bladder.
 12. The sports ball, as recited in claim 6, furthercomprising an adhesive layer provided between said laminating leaves andsaid outer spherical surface of said inflatable ball bladder forproviding an adhesive effect between said laminating leaves and saidinflatable ball bladder so as to securely bind said laminating leaveswith said outer spherical surface of said inflatable ball bladder. 13.The sports ball, as recited in claim 9, further comprising an adhesivelayer provided between said laminating leaves and said outer sphericalsurface of said inflatable ball bladder for providing an adhesive effectbetween said laminating leaves and said inflatable ball bladder so as tosecurely bind said laminating leaves with said outer spherical surfaceof said inflatable ball bladder.
 14. The sports ball, as recited inclaim 1, being manufactured by a method which comprises the steps of:(a) providing said inflatable ball bladder having said outer sphericalsurface; (b) cutting a carcass sheet in said plurality of laminatingleaves; and (c) overlappedly adhering said laminating leaves to saidouter spherical surface of said ball bladder, wherein when saidlaminating leaves are connected edge-to-edge, said spherical casingsform said spherical carcass of said ball bladder.
 15. The sports ball,as recited in claim 13, being manufactured by a method which comprisesthe steps of: (a) providing said inflatable ball bladder having saidouter spherical surface; (b) cutting a carcass sheet in said pluralityof laminating leaves; and (c) overlappedly adhering said laminatingleaves to said outer spherical surface of said ball bladder, whereinwhen said laminating leaves are connected edge-to-edge, said sphericalcasings form said spherical carcass of said ball bladder.
 16. A methodof manufacturing a sports ball, comprising the steps of: (a) providingan inflatable ball bladder having an outer spherical surface; (b)cutting a carcass sheet in a plurality of laminating leaves, whereineach of said laminating leaves, which is constructed from a plurality ofpolygon panels, has a plurality of peripheral alignment edges arrangedin such a manner when said alignment edges are connectedcorrespondingly, said laminating leaves forms a portion of a sphericalcasing; and (c) overlappedly attaching said laminating leaves to saidouter spherical surface of said ball bladder, wherein when saidlaminating leaves are connected edge-to-edge, said spherical casingsform a spherical carcass of said ball bladder.
 17. The method as recitedin claim 16, in step (b), further comprising a step of embossing each ofsaid laminating leaves at said corresponding peripheral alignment edgesto create a predetermined slope thereon with respect to saidcorresponding polygon panels so as to stand out the shapes polygonpanels protruding on said ball bladder when said laminating leaves areattached on said inflatable ball bladder.
 18. The method, as recited inclaim 17, wherein the step (c) comprises the steps of: (c.1) applying anadhesive layer on said outer spherical surface of said inflatable ballbladder; (c.2) aligning each of said peripheral alignment edges with acorresponding adjacent peripheral alignment edge; (c.3) overlapping saidlaminating leaves on said outer spherical surface wherein said adhesivelayer securely binds said laminating leaves with said outer sphericalsurface of said inflatable ball bladder to form said spherical carcassof said sports ball.
 19. The method as recited in claim 17, in step (c),wherein said laminating leaves are overlappedly attached on said ballbladder in a spherical mold machine for minimizing a manufacturing timerequired to sew said laminating leaves together so as to reduce amanufacturing cost of said sports ball.
 20. The method as recited inclaim 18 in step (c), wherein said laminating leaves are overlappedlyattached on said ball bladder in a spherical mold machine for minimizinga manufacturing time required to sew said laminating leaves together soas to reduce a manufacturing cost of said sports ball.
 21. The method,as recited claim 17, wherein each of said laminating leaves isconstructed by five hexagonal polygon panels and three pentagonalpolygon panels integrally extended therefrom in an edge-to-edge manner,so as to form said peripheral alignment edges at said edges of saidhexagonal polygon panels and three pentagonal polygon panelsrespectively.
 22. The method, as recited claim 18, wherein each of saidlaminating leaves is constructed by five hexagonal polygon panels andthree pentagonal polygon panels integrally extended therefrom in anedge-to-edge manner, so as to form said peripheral alignment edges atsaid edges of said hexagonal polygon panels and three pentagonal polygonpanels respectively.
 23. The method, as recited claim 20, wherein eachof said laminating leaves is constructed by five hexagonal polygonpanels and three pentagonal polygon panels integrally extended therefromin an edge-to-edge manner, so as to form said peripheral alignment edgesat said edges of said hexagonal polygon panels and three pentagonalpolygon panels respectively.
 24. The method, as recited in claim 17,wherein said sports ball is formed by four identical pieces of saidlaminating leaves which are to be attached on said inflatable ballbladder for fittedly aligning said corresponding peripheral alignmentedges so as to form said spherical carcass of said inflatable ballbladder, such that each of said laminating leaves form a quarter of saidspherical carcass.
 25. The method, as recited in claim 18, wherein saidsports ball is formed by four identical pieces of said laminating leaveswhich are to be attached on said inflatable ball bladder for fittedlyaligning said corresponding peripheral alignment edges so as to formsaid spherical carcass of said inflatable ball bladder, such that eachof said laminating leaves form a quarter of said spherical carcass. 26.The method, as recited in claim 23, wherein said sports ball is formedby four identical pieces of said laminating leaves which are to beattached on said inflatable ball bladder for fittedly aligning saidcorresponding peripheral alignment edges so as to form said sphericalcarcass of said inflatable ball bladder, such that each of saidlaminating leaves form a quarter of said spherical carcass.